SHOCKLESS
VALVE
OVERHAUL MANUAL
Applicable
Subject part No. Subject model
serial No.
649-15600001 HD1430 From first
805801E
Introduction (C102-0001-2E)
This book is the procedure manual concerning disassembly and assembly and inspection of pneumatic and hydraulic parts
(units) and main equipment (assembly parts).
When disassembling applicable parts, observe the precautions below and work according to this manual.
1. When disassembling hydraulic equipment etc., aim for cleanliness, order and good management.
Particularly when detaching and handling heavy objects from the main body, use a suitable crane or hoist winch.
When disassembling and assembling, use the specified jigs and tools and the regulation torque control.
2. Refer to the "Service Manual" for the procedure when removing and reattaching applicable parts from the main
body of the machine.
3. Always refer to the applicable parts list when replacing parts.
4. When the reassembly of applicable parts is finished, test them as separate units before reattaching to the main body
of the machine.
5. For the test after reattachment, first carry out preoperational checks then operate unloaded.
(0580-0001-0E)
Summary ............................................................................. 1
Structure and operation ....................................................... 1
Disassembly and assembly ................................................. 3
1
A C SLV4-03T-01 E
B 649-15600001 D 2002.12 (LD) F
(0580-0002-0J)
2
1. Summary (0580-0003-0E)
This valve is located between the remote control valve and the main multiple valve. This valve functions so the cylinder
can move smoothly even if the remote control valve is operated roughly. If pilot pressure does not act on this valve, this
valve does not provide shockless function.
2. Structure and operation (0580-0004-0E)
This valve includes valve body [1], pilot cover [2], check plungers [3], orifices [4] and [5], and springs [9] and [10].
Function 1: Structures for sections Y-Y (4 locations) are all the same in the diagram. Orifices [4] and [5] are installed
into check plungers [3] and pressed against the seat sections by springs [10]. A 0.6 orifice is used for orifice
[4] and a 0.8 orifice for orifice [5]. If pilot pressure does not act on port P2 in the diagram, mutual
internal pilot pressure opens check plungers [3] forcedly and this valve does not provide shockless function
when the remote control valve is operated. If pilot pressure acts on port P2, check plungers [3] are pressed
and immobilized by pilot pressure. Only orifices [4] and [5] operate and function effectively so that the
cylinder can move smoothly without shock.
Function 2: A small amount of hydraulic oil flows from port P1 to this valve continually so that the oil temperature in
this valve is the same as that in the tank to improve the response.
Function 3: Ports I N shown in the diagram are used for the swing circuit. Steel ball [21] functions as a shuttle valve.
This valve has three functions as indicated above.
-1-
Ref. No. Part Name Q'ty Ref. No. Part Name Q'ty
1 Body 1 12 Plug 1
2 Pilot cover 1 13 Plug 3
3 Check plunger 4 14 Plug 11
4 Orifice 3 15 Hexagon socket bolt 6
5 Orifice 1 16 Plug 4
6 Plug 4 17 O-ring 4
7 Seat 4 18 O-ring 4
8 Plug 1 19 O-ring 4
9 Spring 4 20 O-ring 4
10 Spring 4 21 Steel ball 5
11 Spring 4 24 Setscrew 1
-2-
3. Disassembly and assembly (0508-0005-0E)
3-1 General precautions (0508-0006-0E)
Disassemble and assemble in a clean workplace and prepare a clean container to put the disassembled parts into.
Clean around the ports before disassembly and remove the paint from each joint section with a wire brush.
Wash all the disassembled parts in cleaning oil such as diesel fuel etc.
Replace the seals with new ones once disassembled and apply grease to them lightly.
3-2 Disassembly procedure (0580-0005-0E)
(1) Clamp body [1] in a vise.
(2) Remove six hexagon socket bolts [15] to detach pilot cover [2].
Tightening torque for hexagon socket bolts: 11.8 14.7N m (1.2 1.5kgf m)
(3) Remove check plungers [3] from body [1].
(4) The special tool is required to remove plugs [6] from check plungers [3].
Remove plugs [6] to detach springs [10] and orifices [4] and [5] from the inside. Replace O-rings [18] with new ones.
(5) Use the hexagonal wrench to remove plugs [16]. Then remove seats [7], steel balls [21] and springs [11].
Replace O-rings [17] and [20] with new ones.
(6) Remove plug [12] and use the hexagonal wrench to remove plug [8]. Then remove steel ball [21] from the inside.
(7) Remove plug [13] and use the hexagonal wrench to remove setscrew [24] from the inside.
(8) Use the hexagonal wrench to remove plugs [14].
-3-
3-3 Assembly procedure (0580-0006-0E)
Replace all the seals with new ones when reassembling.
Wrap sealing tape around the plugs and apply Loctite to them before assembly. Follow the assembly procedure diagram
below for the tightening torque.
-4-
